I N S TRUCT IONSUnloading and InstallingCONTECH TRUSS PIPEfor Sanitary Sewers

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Preface

This instruction booklet is for your crews.Distribute it to help them install CONTECH®

TRUSS PIPE® correctly. TRUSS PIPE is a semi-rigid pipe that is installed followingthe trench construction, bedding, haunching,initial backfill, and other requirements ofASTM D 2680 “Standard Specification forAcrylonitrile Butadiene–Styrene (ABS) andPoly (Vinyl Chloride) (PVC) CompositeSewer Piping.”

Don’t assume experienced workers know allthe answers. Review these instructions withyour supervisors and crews. It can mean abetter job for you and your customer.

We suggest that you adopt a policy of performance testing the first few manholeruns. It will give you an early check thatinstallation procedures are correct. If youhave any questions about these instructions,call your CONTECH TRUSS PIPE Dealer or your CONTECH Sales Engineer, or carefully review ASTM D 2680.

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Contents

PageUnloading and Handling . . . . . . . . . . . . . . . 4Trenching . . . . . . . . . . . . . . . . . . . . . . . . . . 6Embedment Materials . . . . . . . . . . . . . . . . . 7Bedding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . 9Deep Laterals . . . . . . . . . . . . . . . . . . . . . . 10Solvent Welding Joints . . . . . . . . . . . . . . . 11Assembling Gasketed Joints . . . . . . . . . . . 16Installing Saddle Fittings . . . . . . . . . . . . . 18Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . 20Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Mechanical Plugs . . . . . . . . . . . . . . . . . . . 22Field Repair . . . . . . . . . . . . . . . . . . . . . 23-25Laser Beams . . . . . . . . . . . . . . . . . . . . . . . 25Curved Sewers . . . . . . . . . . . . . . . . . . . . . 26Miscellaneous Tips . . . . . . . . . . . . . . . . . . 27Air Testing . . . . . . . . . . . . . . . . . . . . . . 28-30

This safety alert symbol indicatesimportant safety messages. When

you see this symbol, be alert to thepossibility of personal injury and be sureyou understand the message that follows.

Terms You Should KnowAlerts you to hazards orunsafe practices that CAN

result in severe personal injury orproperty damage.

Messages about proceduresor actions that must be

followed for safe handling and installa-tion of TRUSS PIPE.

Unloading and HandlingThe following equipment is recommended for unloading pipe pallets:• Forklift with full-length forks to engage

entire pallet width, front-end loader orbackhoe with fork adapters full-length toengage entire pallet width.

Other loading methods such as hoisting arenot recommended. Do not stand or ride onthe load of pipe while it is being unloaded.NOTE: The pipe is palletized by steel straps around a wood frame. Once the pallet is opened, light interior strapping will maintain the bundle’s shape as individual pipes are removed for use.

Failure to follow these instructions can result in serious injury or death and/or damage to pipe.

1. Only trained and authorized equipmentoperators are to be permitted to unloadthe trailer.

2. Wear approved safety hat and shoes,gloves and eye protection.

3. Park the truck and trailer on level ground before you start unloading.

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4. Keep all unauthorized persons clear ofthe area when the driver releases thebinders from the trailer and duringunloading.

5. Do not cut the 1/2-inch steel strappingaround the wood frame until the palletshave been placed on level ground andwill not be moved again as a unit. It isrecommended that the steel strapping becut with appropriately sized shears orother similar cutting tools.

6. Know the capabilities and rated loadcapacities of your lifting equipment.Never exceed them.

7. Do not stand or ride on the load of pipewhile it is being unloaded.

8. If unloading at multiple points,secure pallets between drop-off points. For each unit of four pallets, always unload the top pallets first (See diagram).

9. Never attach chains or wire rope to thepipe. They could damage the pipe.

10. Do not push pallets off the trailer or permit to drop to the ground.

11. Do not drag TRUSS PIPE across theground.

12. Do not stack TRUSS PIPE over two pallets high. Stacks of three or more pallets can damage bottom pipes and can become unstable.

13. Handle TRUSS PIPE (and other plasticpipe) with extra care in freezing or coldweather. See pages 14 and 27 for additional cold weather installation information.

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General–Trenching and Bedding1. Follow project specifications and OSHA

rules.2. The trench width needs to be only wide

enough to safely allow room for a manto work.

3. The pipe needs a good, uniform supportin the bedding. A granular cushion helpsprovide this. It also makes it easier tolay to grade and line.

4. When using select, native soils, be surethey are finely divided and no largerthan 11/2-inches. If the select, native soilis clay or silt, don’t use it if it’s too wet or too hard and dry.

5. Remove any rock or highly plastic siltand clay from the bed 4 inches to 6inches below the pipe and replace it with a good granular cushion.

6. For best results, keep water out of theworking area in the trench bottom.

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General–Embedment MaterialsEmbedment soils used in semi-rigid thermoplastic pipe installation are describedin ASTM D 2680 Appendix (Class I, II, III,IV Types ML, CL). The embedment soilsshould be capable of being readily densi-fied. Use select, native soils which are free of clods, debris, frozen lumps, rock andstones (or similar object) larger than 11/2-inch.

Pipe/Soil Envelope and Trench ZonesThe moisture content and the plasticity of silt and clay soils have considerable effectupon their usefulness. When these soils arewithin their optimum moisture content range, they can often be worked relativelyeasily, however, when too wet and lumpy,they are unacceptable for use in the embedment zone. They are also unaccept-able as dry, hard clods when soil particle size requirements are exceeded. Lumps orclods create undesirable point loads or disrupt the uniformity of the pipe’s support.

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Select, native soil is free of Class V-Type(frozen earth, debris, organic peat, largerocks, etc.) material, normally finely divided and not highly saturated with water.Concrete is not recommended in the embedment zone because its unyieldingnature can cause problems.

BeddingTo install the pipe true to line and grade,surface grade the bed to obtain a uniform and continuous support below the pipe. Pipe may either be placed upon a uniform and flat bedding surface or into a shaped area conforming to the pipe periphery. Shape or deposit bedding material in thehaunch to stabilize pipe alignment duringsubsequent operations.

Use Class I and II soils in the bedding without special densification efforts. It is usually necessary to densify loose or imported Class III soils. When in undis-turbed native Class IV soils, carefully shapethe bed to conform it to the bottom pipeperiphery and to support the pipe uniformlyand continuously. When select Class IV soils are returned to the bedding, they shall be carefully densified using tampers, lightrollers or similar compaction equipment.

Do not use Class IV soils for bedding whenthey are outside of the optimum moisturecontent range which permits these soils to be worked easily to obtain the uniform andcontinuous support.

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Initial BackfillPlace initial backfill materials in a manner to achieve uniform pipe support and loading over the pipe and bedding. DepositClass I, II, III and allowable Class IVmaterials simultaneously on each side of the pipe to prevent lateral displacement of the pipe, making certain the materials fill the haunch area. Densify as required,paying special attention to Class IV materials.

General–Backfilling1. Follow project specifications and

OSHA rules.2. Keep frozen lumps, junk and rocks of

11/2-inch size and larger a minimum of 6 inches away from the pipe.

3. Place the backfill quickly to avoid floating the pipe, then spread it so thepipe is supported and loaded evenly.

4. A good stomping next to the pipe always helps. Avoid using impact-typepaving breakers or hydro-hammersbecause they may damage the pipe.

5. Don’t block or cradle pipe with hard solid chunks, wood, rock, brick or concrete. The pipe must have uniformsupport.

6. When laterals, risers, or drop manholesare required, the installation must bedesigned to ensure the pipe and fittings are not damaged by loads generated due to soil dragdown and/orpoor installation practices. Generally, assewer depths increase and/or soil quality declines, additional attention

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must be given to these loads to ensure asatisfactory installation. Heavy loads can buckle the lateral pipe or punch itthrough the main sewer. For normal jobsfollow instructions 7 and 8. If the lateralis deep or unusual, ask the engineer and/or the manufacturer for advice.

7. Don’t hang a load on chimneys, risers or stacks as you may damage the pipe orjoint. Tamp as you bring the backfill upevenly around the risers.

8. Backfill carefully underneath and around the lateral pipe where it joins the main sewer.

In order to minimize lateral pipe“punch-through” potential, it is recommended to install wye or tee fittings at an angle no greater than 45º from the horizontal centerline.Stacks (installing wyes or tees at a 90º angle from the pipe horizontalcenterline) should not be allowed.

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Solvent Welding JointsThe CONTECH factory builds the pipe joints to close tolerances. To ensure trouble-free jointing, use only CONTECH primer and cements. These are specially formulatedfor TRUSS PIPE.

The primer softens the plastic surfaces andthe cement seals the joint. The joint driestight after you apply the primer and cementand “push the spigot home.” Home marks are provided.

Follow These Steps1. Apply plenty of primer and cement on

the spigot and inside the bell. Use a johnny mop or brush. Don’t pour primeron. Care should be taken to seal the truss sections when entering and exitingmanholes to avoid false air tests (see Page 29).

2. Apply cement the same way – immediately.

3. Without delay, give the spigot a twistwhile pushing it to the home mark. Arope sling around the pipe has worked on big pipe, with a push from the backend.

4. Use a bar and block to push the spigot all the way home on big pipe and anytime the pipe isn’t twisted home.

5. Wipe excess cement off pipe.6. Where local specifications and practices

allow, ABS-to-ABS solvent welds may be made without using primer when temperatures are above 40º F and conditions are dry. All PVC solvent welds require primer.

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Solvent Welding PVC(PVC to PVC or ABS)PVC pipe and fittings are white. ABS pipeand fittings are black (or dark gray).

1. White PVC TRUSS PIPE joints are made using CONTECH purple primerand blue PVC cement is used for all bell-to-spigot (PVC to PVC) and allTRANSITION (PVC to ABS) joints. Do not use ABS cement.

2. Thoroughly dry both the bell and spigotof wet pipe with a rag. Use liberalamounts of primer on both the bell andspigot. (For transition joints (PVC toABS) use the ABS primer (MEK) withthe PVC cement.)

3. Underwater jointing or jointing withwater standing in the bell is not recommended. Dewater the trench.

4. Do not thin PVC cement with primer.Discard if cement becomes too thick tospread evenly.

5. When temperatures are near zero:a. Follow cold weather jointing

practices (See Page 14, Items 3, 4,and 5).

b. Backfill immediately so the joint cancure at warmer ground temperatures.

c. Allow two weeks cure before air testing.

d. Do not disturb the joint during thiscure period.

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Solvent Welding ABS (ABS to ABS)ABS pipe and fittings are black (or darkgray).

1. ABS TRUSS PIPE joints are made using black CONTECH ABS cement.

2. Underwater jointing is more difficult and risky. The primer and cement won’tstick to the surface when applied belowwater or when the surfaces are wet. Ifyou choose not to dewater the trench,then pre-prime and scrub the primer in.Apply primer and cement liberally. Twist as you drive the spigot home. Avoid moving the joint after you finish.Allow to cure for 2-3 days prior to running air test.

3. The cement can dry and thicken. Thin,but don’t over-thin, with primer. Stir tokeep it a like a rich latex paint–as it was shipped to you.

4. For jointing in cold or wet weather, seethe tips on Page 14, Items 3, 4, and 5.

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Solvent Welding Tips1. When a cement bead about as thick as

the coupling appears around the bell after the spigot is home, you have made a good joint.

2. Primer and cement dry out more quicklyin hot and dry weather. If a skin forms on the pipe, you have waited too long tomake your joint. When this happens,clean the surfaces with primer and re-cement. At such times, work faster andkeep the primer and cement containersclosed.

3. In cold, wet weather the joint sets upmore slowly. If a trench box or shield isbeing used, you should stake the last pipe before moving the box to preventdisjointing.

4. When temperatures are cold or belowfreezing, pre-prime the bell and spigot by scrubbing the primer in. Then with the surfaces still soft, follow the normaljointing procedure.

5. When you pre-prime, allow plenty oftime for the primer to soften the material, or scrub it in longer.

6. Re-push the joint right away if it wasmoved to set grade, and be sure the pipeis homed.

7. After joining, cover the pipe with backfill, but only after the joint is tightand cement has surface hardened.

8. Allow adequate cure time prior to air testing.

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Joining Solvent Welded TRUSS PIPEand FittingsTo make ABS solvent welds, use CONTECH ABS cement (black) with MEK primer.To make PVC solvent welds, use CONTECH PVC cement (blue) with PVCprimer (purple). Note: Solvent welding PVC in standing or running water is not recommended.

Primer and Cement Requirements for Making Solvent Weld Pipe Joints

Cement and Primer Usage(Joints per Gallon)

Pipe Size Primer Cement

4” 125 866” 55 388” 40 28

10” 28 2012” 21 1515” 14 10

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Assembling Gasketed Joints(No primer or cement required)The gasket is factory-installed in the bell. The joint cannot be assembled without proper lubrication. Follow these steps:

1. Thoroughly clean the bell and spigot.Make certain the gasket is seated properly.

2. Apply liberal amounts of gasket lubricant to the gasket and to the spigot end.a. Use a johnny mop or brush.b. Do not remove the gasket from the

bell after it is lubricated or to applylubricant.

c. Make certain the outer edge of thespigot is well lubed.

3. Align the joint and push the spigot to the home mark using a bar and blockfrom the back end. Take care so the wood block protects the pipe end fromthe bar. On larger diameters, come-alongs, a choker, etc. may be beneficial in starting the pipe stab. Be careful not to overinsert.

4. Chamfer the outer pipe wall on fieldcut spigot ends. File to remove all burrs and rough spots.

5. If a trench box or shield is being used,the last pipe may require staking beforethe box is moved to prevent disjointing.

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Joining PVC Gasketed Pipe and Fittings(ASTM D 3212)

Lubricant Requirements(Joints per Gallon)

Pipe Size Lubricant

4” 3006” 2208” 100

10” 6412” 4815” 25

1. Read safety precautions listed on primerand cement cans.

2. Keep both primer and cement away fromopen flames. Treat like gasoline.

3. Avoid prolonged breathing of vapors intight places like manholes.

4. May be fatal if swallowed.5. Prevent primer and cement from getting

in your eyes. If it does, wash your eyeswith water for 10 to 15 minutes. Consulta doctor immediately.

6. If you are working in closed spaces andbecome ill, see a doctor and tell him that you were exposed to a plastic pipeprimer. Cements contain:• ABS primer is methyl ethyl keytone

(MEK).• ABS cement contains MEK and ABS

solids.• PVC primer contains tetrahydorfuran,

MEK, and cyclohexanone.• PVC cement contains tetrahydrofuran,

cyclohexanone, MEK and PVC solids.

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Solvent Welded Saddle1. Stick template on TRUSS PIPE to mark

outline of hole required.2. Use keyhole, slow speed saber saw or

other instruments to cut hole. Don’t starta hole with hammer or hatchet. Use adrill, awl or other sharp cutting tool. This is especially important for PCVTRUSS PIPE in cold weather.

3. Place steel bands loosely around pipe and then apply primer and cement liberally to entire area of pipe and underside of saddle–the same as with a joint.

4. Immediately place saddle firmly onpipe and tighten two stainless steelbands around pipe and saddle. Leavestraps on.

Installing BushingsSolvent weld as instructed for pipe joints(Pages 12 to 16).

Be sure that the bushing is placed so thatthe closed end of the double wall faces thebell (see arrow).

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Manhole Water StopsWhere manhole boots or A-lok type gasketsare not used, grout the connection after putting a manhole water stop on the pipe near the center of the manhole wall. Gasketfins point to manhole outside. Use a screwdriver to pull the slack out of the steelband. A 5/16-inch socket wrench will finishthe tightening.

Manhole stops are needed to stop leaksbecause concrete won’t bond easily to theplastic.

Other Manhole ConnectionsRubber boots and other types of flexible connections between the pipe and manholeshould be installed according to manufacturer’s instructions.

Construction at ManholesExtra care is required to build the proper support around the pipe which enters or exits a manhole. Using Class I or II soils orhand tool densified Class III soil is usuallythe more cost-effective procedure to prevent excessive shearing forces from developing.

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AdaptersPages 20 and 21 show the standard adapters for 4-inch and 6-inch lateral pipe. When using the rubber sleeves for clay pipe, be sure to cut the plastic seating off the clay pipe spigot before connecting.

Other Pipe Spigot Use CONTECH Adapter No.

Type I clay F442 F662F443 F663F444 F664

Type III clay F492 F662(has O-Ring) F493 F663

F494 F664

Cast iron Fernco(plain end) 1056-44 for 4”

1056-66 for 6”

ABS or PVC 4” or 6” todrain waste Sch. 40 or DWV

and vent spigot

Above or Use CONTECH,larger than Fernco or equal

6” pipe

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Joint Sketch How Sealed

Tighten straps overrubber adapter

Compress spigot rubberor O-Ring

Tighten straps overrubber coupling

Solvent weld

Donut or coupling CONTECH, Ferncoor equal

+Clean clay pipe spigot–no plastic end casing left onpipe. This rubber adapter is preferable because itcompensates for the variable dimensions of clay pipeexisting throughout installation.

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Caps and PlugsSolvent weld caps in place.

4” & 6” Spigot CapsNote that bell caps won’t fit over 4-inch and6-inch pipe belled ends.

In placing plugs, be sure the rubber part ispast the shoulder of the bell into the pipe and tighten the fly nut well. Don’t use lubricants. Block and stake mechanical plugs.

Mechanical plugs must not be used for airtesting!

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Field RepairsDamaged TRUSS PIPE can be repaired/replaced using either flexible rubber couplings or PVC couplings. Follow thesesteps to install the new section using two flexible rubber couplings:

1. Cut out damaged areas and cut a lengthof replacement pipe to just fit.

2. Expose the existing cut pipe ends to giveworking room under them.

3. Install a flexible rubber adapter on eachend of the replacement section using gasket lube or vegetable oil as a lubricant.Slide the adapters (or roll them) back andposition the replacement section.

4. Slide (or roll) the adapters over the jointat each end of the replacement section sothat they are centered over the joint.Gasket lube or vegetable oil can be usedas a lubricant.

5. Install and tighten the stainless steelbands, making certain they are positionedproperly.

6. Where specifications require, a plasticshear stop is available. This split ring fitsover the rubber coupling, between thestainless steel bands. It is held in placewith two additional stainless steel bands.

7. Tamp bedding material under the jointswhere it was disturbed to gain workingroom.

Small holes and breaks can be repaired bysolvent welding patches made from palletpacking coupling or split couplings. Followthe procedure for applying saddle fittings(Page 18, Steps 3 and 4).

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Follow these steps to install the new sectionusing two PVC repair couplings.

1. Chamfer outer edge of TRUSS PIPEwall.

2. Clean thoroughly and lube liberallyremaining pipe spigots approximately 11/2 times the coupling length.

3. Push repair coupling in position allowing 3” to 4” of spigot to extendbeyond coupling.

4. Cut replacement length as close as possible to length that was removed.

5. Chamfer both ends of outer edge of outerwall of new length and mark both endsof replacement piece half the length ofthe repair coupler.

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6. Lube liberally the ends of the replace-ment length and in front of repair coupling on existing lengths.

7. Align replacement length with existingspigots and push repair couplings tohomemarks.

Laser BeamsYou must use an adequate blower, becausefumes from curing solvent welded joints ortemperature changes can deflect the beam and throw you off line and grade.

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Curved SewersCurved sewers are built by cocking the jointslightly and using either straight or 3º couplings. The 3º coupling is shipped looseand its top is marked. That mark should be on top when the joint is made.

The following chart and sketch provide necessary installation data.

Minimum Radius of Curvature

Pipe Std. Coupling 3º Loose CouplingDiameter 12’-6” 6’-3” 12’-6” 6’-3”

8” 380’ 190’ 105’ 53’10” 480’ 240’ 130’ 65’12” 580’ 290’ 140’ 70’15” 720’ 360’ 160’ 80’

Allowable Play

Pipe Diameter 8 10 12 15Play in Couplings 51.9º 51.5º 51.25º 51.0º

Plan View of Curvilinear Assembly

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Miscellaneous Tips1. When square cutting pipe with saw, rest

pipe on shipping separators for bestresults.

2. If laying pipe through manhole, leavecutout section in place until you featherconcrete over the cut in wall.

3. Avoid cement buildup inside at jointswhen deflection tests are run.

4. String only enough pipe to use during the day’s laying operations.

5. Except at manhole entries, don’t pourconcrete against or encase the pipe inconcrete.

6. Handle the pipe more gently in coldweather. When placing embedment materials in deep trenches at near zerotemperatures, it may be desirable to usesmaller aggregate (3/8-inch), a stonebucket for placement, or to otherwiseblind the pipe before dumping coarseaggregates.

7. Joining is affected by cold temperatures;gaskets lose compressibility and PVCbells are more brittle. Proper bell-spigotalignment, adequate lubrication andusing recommended joining procedures(i.e. bar and block) are more important in cold weather.

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Testing–False Air Test

The last length of pipe going into the manhole may experience a false air test at the upstream end of a line. The factory side of the coupling is sealed at the center stopand the inner wall of the TRUSS PIPE.However, the last joint at the upstream endhas an exposed spigot end in the coupling. Air may bleed through the grout into themanhole, indicating a leak but is actually afalse air test. The air is passing between thepipe walls into the manhole even thoughjoints are air-tight.

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To minimize or prevent false air test occurrence...

For solvent welded jointsCoat the exposed mearlcrete in the spigotends with solvent cement during joining.

For gasketed and solvent welded jointsFollow the “reverse jointing” procedure at the upstream manhole detailed below:

Pipe is inlaid in a normal (spigot to bell) fashion until within 25’ of upstream manhole.

Cut a section of TRUSS PIPE (spigot x spigot) and join in a normal spigot into bellfashion. * Length should be as required toleave a 12.5’ gap to the manhole.

*Use the remaining bell x spigot piece fromthe cut as the second piece to exit the otherside of the manhole.

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A standard 12.5’ TRUSS PIPE section should be used for entry (and exit) into themanhole. Slide the spigot end into the manhole, and pull the section out until thebell joins the spigot of the previouslyinstalled pipe.

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NOTES

Your CONTECH Sales Engineer is:

_____________________________________

_____________________________________

_____________________________________

Home phone number ____________________

City _________________________________

Nearest office phone ____________________

City _________________________________

NOTHING IN THIS CATALOG SHOULD INANY WAY BE CONSTRUED AS AN EX-PRESS WARRANTY OR AS EXTENDINGTO THE READER OR BUYER ANY IM-PLIED WARRANTY INCLUDING BUTNOT LIMITED TO THE IMPLIED WARRAN-TIES OF MERCHANTABILITY OR FITNESSFOR ANY PARTICULAR PURPOSE. Speci-fications and data referring to mechanical andphysical properties or chemical analyses relatesolely to tests performed at the time of manu-facture on specimens obtained from specificlocations of the products in accordance withprescribed sampling procedures. For specificterms and conditions of sale, refer to standardCONTECH documents.

CONTECH and TRUSS PIPE are registered trademarks of Contech Engineered Solutions.

©2013 Contech Engineered Solutions LLCWest Chester, Ohio All rights reserved.

www.ContechES.com/safety

NOTHING IN THIS CATALOG SHOULD BE CONSTRUED AS AN EXPRESSED WARRANTY OR AN IMPLIED MERCHANTIBILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. SEE THE CONTECH STANDARD CONDITIONS OF SALE (VIEWABLE AT WWW.CONTECHES.COM/COS) FOR MORE INFORMATION.

CONTECH, HEL-COR, PAVED-INVERT, SMOOTH-FLO, and ULTRA FLO are registered trademarks of Contech Engineered Solutions LLC. ALUMINIZED STEEL is a trademark of AK Steel Corporation.

For additional safety information, visit www.conteches.com/safety.

©2013 Contech Engineered Solutions LLC. All rights reserved. Printed in USA.

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